Method for manufacturing a tree-dimensional puzzle

ABSTRACT

A three-dimensional puzzle including a lenticular lens layer having a lens surface and a flat surface. A four color ink is applied to the flat surface and a layer of opaque ink is applied to the four color ink. A white paper backing is adhered to the layer of opaque ink using an emulsion based adhesive having a viscosity of approximately 1,600 mPas at 23° C., and a backer board comprised of four layers of cardboard is applied to the white paper backing. A method of manufacturing the three-dimensional puzzle is also disclosed.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This patent application is a divisional of copending U.S. patentapplication Ser. No. 10/993,120, filed Nov. 19, 2004, the content ofwhich is incorporated herein by reference in its entirety for allpurposes.

FIELD OF THE INVENTION

This invention pertains to puzzles in general and, more particularly, tothree-dimensional puzzles.

BACKGROUND OF THE INVENTION

Puzzles have long been a source of entertainment and enjoyment forindividuals both young and old. For the youngest child, puzzles whichusually involve a few large pieces, serve not only as entertainment, butalso help to develop coordination along with color and shaperecognition. As children get older, puzzles with many smaller piecesbecome popular as they offer more of a challenge to build than puzzleswith large pieces.

Because the pieces of a puzzle can only be cut so small in order for thepuzzle to be practical to construct, puzzle manufacturers must continueto come up with new ways to make the puzzle challenging. This is done,for example, by making the puzzle from a multi-colored picture or usingscenes where colors blend in with one another such as the reds, yellowsand orange of a sunset or the various shades of blue and green involvedwith a seascape. A three-dimensional puzzle gives the added dimension ofdepth to the scene, thereby making it more difficult to construct.

Three-dimensional puzzles are known in the art. For example, U.S. Pat.No. 6,547,243 (Juenger) discloses a portable three-dimensional puzzlehaving a magnetic backing that makes it easier to use when traveling.Furthermore, U.S. Pat. No. 5,896,230 discloses a method for producing amultidimensional image using a lenticular lens.

Three-dimensional puzzles that can be cut into several small pieces,such as a 500 piece puzzle set, are not well known, however. This isbecause when cutting the photographic sheet into a puzzle, the greaterthe amount of rule in a square inch, the greater the amount of tensionor pressure in the sheet. In other words, the larger the pieces of thepuzzle, the less pressure involved in cutting them.

The greater pressure involved in cutting a puzzle into numerous smallpieces causes the backing board to weaken, thus causing the images onthe puzzle pieces to delaminate. This decreases the sharpness of theimage and results in cloudy condition on the edges of the puzzle piece.For this reason, a three-dimensional puzzle that is capable of being cutinto numerous small pieces without causing deterioration of the image ofthe puzzle would be an important improvement in the art.

BRIEF SUMMARY OF THE INVENTION

The invention is directed to a puzzle comprised of a lenticular lenslayer having a lens surface and a flat surface. A layer of four colorsof ink is applied to the flat surface and a layer of opaque ink isapplied to the four colors of ink. A white paper backing is adhered tothe layer of opaque ink using an emulsion based adhesive having aviscosity of approximately 1,600 mPas at 23° C., and a backer boardcomprised of four layers of cardboard is applied to the white paperbacking.

The invention also involves a method of manufacturing athree-dimensional puzzle. The method is comprised of the steps of: (a)providing a lenticular lens layer having a lens surface and a flatsurface; (b) applying a layer of four colors of ink to the flat surfaceof the lenticular lens layer; (c) providing a first exposure ofultraviolet light to the layer of four colors of ink; (d) adding a layerof opaque ink to the layer of four colors of ink; (e) providing a secondexposure of ultraviolet light to all layers of the puzzle; (f) providinga third exposure of ultraviolet light to all layers of the puzzle; (g)providing a fourth exposure of ultraviolet light to all layers of thepuzzle; (h) providing a fifth exposure of ultraviolet light to alllayers of the puzzle; (i) adhering a layer of white paper backing on topof the layer of opaque ink; and (j) attaching a backer board on top ofthe layer of white paper backing.

A method for cutting the puzzle is also disclosed. This involves thesteps of (a) providing a cutting platform; (b) cutting at least onegroove in the platform, the groove forming the shape of at least onepuzzle piece; (c) positioning a cutting instrument in the at least onegroove; (d) placing a piece of rubber over the cutting instrument; (e)inserting at least one insert in at least one location between therubber and the cutting platform; and (f) pressing the three-dimensionalpuzzle over the cutting instrument, thereby cutting thethree-dimensional puzzle into at lest one puzzle piece.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic showing the layers of the three-dimensionalpuzzle.

FIG. 2 is a schematic view of the steps of the puzzle manufacturingmethod.

FIG. 3 is a top view of a puzzle piece.

DETAILED DESCRIPTION OF THE INVENTION

The following examples further illustrate the invention but, of course,should not be construed as in any way limiting its scope. As shown inFIGS. 1-3, the invention involves a puzzle 10 comprised of a lenticularlens layer 12 having a lens surface 14 and a flat surface 16. A layer offour colors of ink 18 is applied to the flat surface 16, and a layer ofopaque ink 20 applied to the four colors of ink 18. A white paperbacking 22 is adhered to the layer of opaque ink 20 using anemulsion-based adhesive having a viscosity of approximately 1,600 mPasat 23° C., and a backer board 24 comprised of four layers of cardboardis applied to the white paper backing 22.

In one embodiment, the puzzle 10 is further comprised of a layer ofprimer 26 located between the flat surface 16 of the lenticular lenslayer 12 and the layer of four colors of ink 18. The primer is a UV/EBCurable adhesive, primer, coating that is sold under various trade namesincluding Rad-Cure, Rad-Kote and Rad-Prime.

The lenticular lens layer 12 used with the puzzle 10 has a thickness inthe range of approximately at least 10 to approximately at least 15 mil,and more preferably approximately 14 mil. Furthermore, each of thelayers of the four layer backer board 24 is perpendicular to theiradjoining layers, and the four layer backer board 24 has a thickness ofapproximately 1.25 mm.

The layer of four colors of ink 18 used with the puzzle 10 can be anultraviolet lamination formulation or a hybrid ultraviolet formulation.The opaque ink may be white.

As shown in FIG. 3, the invention also involves a method formanufacturing a three-dimensional puzzle 10, the method comprising thesteps of: (a) providing a lenticular lens layer 12 having a lens surface14 and a flat surface 16; (b) priming the flat surface 16 of thelenticular lens layer 12; (c) exposing the primed flat surface 16 of thelenticular lens layer 12 to ultraviolet light; (d) applying a layer offour colors of ink 18 to the flat surface 16 of the lenticular lenslayer 12; (e) providing a first exposure 28 of ultraviolet light to thelayer of four colors of ink 18; (f) adding a layer of opaque ink 20 tothe layer of four colors of ink 18; (g) providing a second exposure 30of ultraviolet light to all layers of the puzzle 10; (h) providing athird exposure 32 of ultraviolet light to all layers of the puzzle 10;(i) providing a fourth exposure 34 of ultraviolet light to all layers ofthe puzzle 10; (j) providing a fifth exposure 36 of ultraviolet light toall layers of the puzzle 10; (k) adhering a layer of white paper backing22 on top of the layer of opaque ink 20; and (l) attaching a backerboard 24 on top of the layer of white paper backing 22.

In the inventive method, once the primer is applied, the primed flatsurface 16 of the lenticular lens 12 is cured using exposure toultraviolet light of approximately 840 watts for less than one second.

The four colors of ink used with the invention are comprised of black,cyan, magenta and yellow inks. In one embodiment, the black ink is firstapplied to the lenticular lens 12, the cyan ink is applied second, themagenta ink is applied third, and the yellow ink is applied fourth.These four colors of ink may be printed using stochastic screen printingmethods; however, conventional screening methods may also be usedwithout departing from the scope and spirit of the invention.

When performing the inventive method, after the layer of the four colorsof ink 18 is applied, the puzzle is exposed to approximately 1,120 wattsof ultraviolet light for less than one second. Following this exposure,a layer of opaque ink 20, which may be white, is added. The layers ofthe puzzle are then given another exposure to ultraviolet light, thistime the exposure being approximately 1,330 watts of ultraviolet lightfor less than one second. Once this exposure is complete, the layers ofthe puzzle are exposed to approximately 840 watts of ultraviolet lightfor less than one second. This exposure is followed by a still anotherexposure of ultraviolet light to the layers of the puzzle 10. Thislatest exposure being approximately 1,120 watts of light for less thanone second. Finally, the layers of the puzzle 10 are exposed toultraviolet light for a final time, this final time being approximately1,190 watts of light for less than one second.

In constructing the puzzle 10, the layer of white paper backing 22 isapplied to the layer of opaque ink 20 using a polyacid adhesive. Thebacker board layer 24 is then applied to the white paper backing layer22 using a conventional glue or adhesive.

The lenticular lens 12 used in constructing the puzzle 10 has athickness in the range of approximately 10 to approximately 15 mil, andmore preferably approximately 14 mil. This is because a lenticular lenshaving a thickness less than approximately 10 mil tends to alter thevisual appearance of the puzzle by distorting the perception of depth.On the other hand, although a thickness greater than 15 mil produces agreater perception of depth to the viewer, it is more difficult to cutwithout causing the images on the puzzle pieces to delaminate, therebydecreasing the sharpness of the image.

Although puzzles having a lenticular lens with a thickness ofapproximately 18 mil are known, these puzzles are a 2-image fliplenticular, not three-dimensional puzzles. A 2-image flip lenticular isa puzzle that allows one to see two different images depending on howthe puzzle is tilted. Because of the thickness of the lens, it isdifficult to cut the puzzle into anything smaller than a few largepieces that are common in children's puzzle. In fact, puzzles utilizinga lenticular lens that is 18 mil thick have been discontinued in that itis cost prohibitive to cut a puzzle having a lens of this thickness intosmaller pieces such as those used in 250 or 500 piece puzzles.

The backer board 24 used in the inventive puzzle is comprised of fourlayers of cardboard. This four-layer backer board 24 has a thickness ofapproximately 1.25 mm and each of the four layers of cardboard areoriented perpendicular to their adjacent layers.

The method of manufacturing the puzzle 10 may also involve the steps of(a) providing a cutting platform; (b) cutting at least one groove in theplatform, the groove forming the shape of at least one puzzle piece; (c)positioning a cutting instrument in the at least one groove; (d) placinga piece of rubber over the cutting instrument; (e) inserting at leastone insert in at least one location between the rubber and the cuttingplatform; and (f) pressing the three-dimensional puzzle over the cuttinginstrument, thereby cutting the three-dimensional puzzle into at leastone puzzle piece 40, as shown in FIG. 3.

In one embodiment of the inventive method, the at least one groove ispart of a plurality of grooves. This plurality of grooves form theshapes of a plurality of puzzle pieces, and the pressing of thethree-dimensional puzzle over the cutting instrument, cuts thethree-dimensional puzzle into a plurality of puzzle pieces. Once thepuzzle has been cut into a plurality of pieces, the plurality of puzzlepieces are then separated from one another. This is done when the puzzleis “crushed” for packaging. When the puzzle is crushed for packaging,special rubber tips are affixed to the “teeth” in the delivery portionof the packaging machine. These rubber tips provide the additional forceneeded to separate the pieces without marring the image on the puzzle.

The cutting instrument used to cut the puzzle may be a double-sharpened,hardened steel rule or knife that uses harder steel than is normallyassociated with puzzle die-cutting. This knife has a body and a bladewith the hardness of the body being at least approximately 39 HRC, andthe hardness of the blade being at least approximately 57 HRC.

The rubber used in the cutting process may be ejection rubber having athickness of approximately 7 mm and a hardness of approximately 45shore. This is a more rigid material than is normally used in puzzlecutting. Additionally, a plurality of inserts may be positioned in aplurality of locations between the rubber and the cutting platform. Thisplurality of inserts may vary the height of the ejection rubber fromapproximately 0.001 mm to approximately 0.01 mm at certain locations inthe die. This altering of the height of the ejection rubber allows for aclean cut across the entire surface of the puzzle.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. Recitation of ranges of values herein are merely intended toserve as a shorthand method of referring individually to each separatevalue falling within the range, unless otherwise indicated herein, andeach separate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein, isintended merely to better illuminate the invention and does not pose alimitation on the scope of the invention unless otherwise claimed. Nolanguage in the specification should be construed as indicating anynon-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention. Itshould be understood that the illustrated embodiments are exemplaryonly, and should not be taken as limiting the scope of the invention.

1. A method of manufacturing a three-dimensional puzzle, comprising thesteps of: providing a lenticular lens layer having a lens surface and aflat surface; priming the flat surface of the lenticular lens layer;exposing the primed flat surface of the lenticular lens layer toultraviolet light; applying a layer of four colors of ink to the flatsurface of the lenticular lens layer; providing a second exposure ofultraviolet light to the layer of four colors of ink; adding a layer ofopaque ink to the layer of four colors of ink; providing a thirdexposure of ultraviolet light to all layers of the puzzle; providing afourth exposure of ultraviolet light to all layers of the puzzle;providing a fifth exposure of ultraviolet light to all layers of thepuzzle; providing a sixth exposure of ultraviolet light to all layers ofthe puzzle; adhering a layer of white paper backing on top of the layerof opaque ink; and attaching a backer board on top of the layer of whitepaper backing.
 2. The method of claim 1, wherein the primed flat surfaceof the lenticular lens layer is cured using exposure to ultravioletlight of approximately 840 watts for less than one second.
 3. The methodof claim 1, wherein the four colors of ink is comprised of black, cyan,magenta and yellow inks.
 4. The method of claim 1, wherein the layer offour colors of ink is applied using stochastic screening.
 5. The methodof claim 1, wherein the second exposure of ultraviolet light to thelayer of four color is approximately 1,120 watts for less than onesecond.
 6. The method of claim 1, wherein the third exposure ofultraviolet light to the layers of the puzzle is approximately 1,330watts for less than one second.
 7. The method of claim 1, wherein thefourth exposure of ultraviolet light to the layers of the puzzle isapproximately 840 watts for less than one second.
 8. The method of claim1, wherein the fifth exposure of ultraviolet light to the layers of thepuzzle is approximately 1,120 watts for less than one second.
 9. Themethod of claim 1, wherein the sixth exposure of ultraviolet light tothe layers of the puzzle is of approximately 1,190 watts for less thanone second.
 10. The method of claim 1, wherein the layer of white paperbacking is applied to the layer of opaque ink using a polyacid adhesive.11. The method of claim 1, wherein the lenticular lens has a thicknessof at least approximately 10 mil.
 12. The method of claim 1, wherein thelenticular lens has a thickness in the range of approximately 10 mil toapproximately 15 mil.
 13. The method of claim 1, wherein the backerboard is comprised of: four layers of cardboard; each of the four layersof cardboard are oriented perpendicular to their adjacent layers; andthe four-layer backer board has a thickness of approximately 1.25 mm.14. The method of claim 1, further comprising the steps of: providing acutting platform; cutting at least one groove in the platform, thegroove forming the shape of at least one puzzle piece; positioning acutting instrument in the at least one groove; placing a piece of rubberover the cutting instrument; inserting at least one insert in at leastone location between the rubber and the cutting platform; and pressingthe three-dimensional puzzle over the cutting instrument, therebycutting the three-dimensional puzzle into at least one puzzle piece. 15.The method of claim 14, wherein: the at least one groove is part of aplurality of grooves; the plurality of grooves forms the shape of aplurality of puzzle pieces; and pressing the three-dimensional puzzleover the cutting instrument, cuts the three-dimensional puzzle into aplurality of puzzle pieces.
 16. The method of claim 14, wherein: thecutting instrument is comprised of a double-sharpened, hardened steelknife; the knife has a body and a blade; the hardness of the body is atleast approximately 39 HRC; and the hardness of the blade is at leastapproximately 57 HRC.
 17. The method of claim 14, wherein the rubber isejection rubber having a thickness of approximately 7 mm and a hardnessof approximately 45 shore.
 18. The method of claim 14, wherein aplurality of inserts are positioned in a plurality of locations betweenthe rubber and the cutting platform.
 19. The method of claim 14, whereinthe plurality of inserts vary in height from approximately 0.001 mm toapproximately 0.01 mm.
 20. A method for cutting a puzzle, the methodcomprising the steps of: providing a cutting platform; cutting at leastone groove in the platform, the groove forming the shape of at least onepuzzle piece; positioning a cutting instrument in the at least onegroove; placing a piece of rubber over the cutting instrument; insertingat least one insert in at least one location between the rubber and thecutting platform; and pressing the three-dimensional puzzle over thecutting instrument, thereby cutting the three-dimensional puzzle into atleast one puzzle piece.
 21. The method of claim 20, wherein: the atleast one groove is part of a plurality of grooves; the plurality ofgrooves forms the shape of a plurality of puzzle pieces; and pressingthe three-dimensional puzzle over the cutting instrument, cuts thethree-dimensional puzzle into a plurality of puzzle pieces.
 22. Themethod of claim 20, wherein: the cutting instrument is comprised of adouble-sharpened, hardened steel knife; the knife has a body and ablade; the hardness of the body is at least approximately 39 HRC; andthe hardness of the blade is at least approximately 57 HRC.
 23. Themethod of claim 20, wherein the rubber is ejection rubber.
 24. Themethod of claim 23, wherein the ejection rubber has a thickness ofapproximately 7 mm and a hardness of approximately 45 shore.
 25. Themethod of claim 23, wherein a plurality of inserts are positioned in aplurality of locations between the rubber and the cutting platform.